Reinforced brick masonry wall and brick therefor



April 14, 1959 R. B. TAYLOR ETAL 2, REINFORCED BRICK MASONRY WALL ANDBRICK THEREFOR Filed June 25, 1955 4 h t he t 1 INVENTORS.

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April 14, 1959 R. B. TAYLOR ET AL REINFORCED BRICK MASONRY WALL ANDBRICK THEREFOR i 4 Sheets-Sheet 2 Filed June 23, 1955 fiv w a A TTORNEYS.

April 14, 1959 R. B. TAYLOR ET AL ORCED BRICK MASONRY WALL AND BRICKTHEREFOR REINF 4 Sheets-Sheet 3 Filed June 25, 1955 I jade/7222?:

April 14, 1959 R. B. TAYLOR ET AL REINFORCED BRICK MASONRY WALL ANDBRICK THEREFOR Filed June as, 1955 f 4 h e 4 I. f /00 ms' muw'w i I L1:5 WW

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United States Patent Robert B. Taylor, Elmhurst, and Paul V. Johnson,Park Forest, 11]., assignors to Structural Clay- Products ResearchFoundation, Geneva, 11]., a trade association Application June 23, 1955,Serial No. 517,452

2 Claims. (CI. 72-40) The present invention relates to the general artof brick masonry. More particularly the invention contemplates aparticular form of brick unit as well as a unique single wythereinforced wall which may be erected using the brick unit. Thespecification and claims as well as the drawings form a continuation inpart of application Serial Number 234,226, filed June 29, 1951, nowabandoned.

Brick masonry walls are constructed in a variety of ways and use avariety of materials depending on the geographic area and the desiredaccomplished of the wall. The exterior row or wythe of bricks in a loadbearing wall is almost universally reinforced or backed up by a secondwythe of bricks or tile; or by concrete blocks; or by an elaboratesystem of wood studding; or by an intricate framework and form ofreinforcing rods and wire; or by a combination of any one or more ofthese structures or systems. The employment of any of these systems orstructures in the reinforcement and back-up of brick walls makes theconstruction of the complete wall expensive and requires a greaternumber of man hours than a finished brick wall constructed according toour invention.

The instant invention contemplates the use of a unique form of brickwhich is built in a conventional manner into a single-wythe load bearingwall. The brickunits when properly placed into the wall form, at spacedin- These channels generally receive reinforcing rods and are filledwith grout. The grout is retained in the channels by means of a moldform which also allows the grout to fill the form resulting in areinforcement for the wall when the grout has set. Particularly with amodified brick unit the poured grout is keyed into position and lockedin place against displacement either laterally or longitudinally.

The mold may be provided with spaced openings to receive nails so thatnails will be imbebbed in the reinforecements when the mold is removed.Insulation, lath and plaster or structural clay products may then beapplied to finish the wall.

By employing the unique form of brick and technique for wallconstruction, the use and added expense of an intricate network and formof reinforcing rods is eliminated and made unnecessary. Likewise, anelaborated and expensive method of using and attaching wooden studs tothe wall is obviated. Additionally, a satisfactory load bearing wall canbe constructed in a shorter period of time and at a lower cost.

The particular brick unit contemplated by the invention provides manyunusual features, all of which may be achieved .with a single type unit,thereby insuring against confusion at the construction site. By themasons following the simple rule: lay like ends together, the wall maybe erected with uniform spacing for reinforcing. Upon building cornersthe additional advantage may be achieved of providing a pair of closelyspaced reinforcements in close proximity to the corner impartingadditional strength at the joint.

2,881,613 Patented Apr. 14, 1959 all It is therefore a general object ofthis invention to provide a load bearing brick wall wherein the bricksof uniform configuration, when placed properly into a wall, formchannels used for reinforcing the wall.

Another object of this invention is to provide a reinforced brickmasonry wall which is simple to construct, durable and inexpensive toerect.

Another object of this invention is to provide a singlewythe brick wallhaving the requisite strength and rigidity without employing anelaborate framework of reinforcing rods or back-up material.

A further object of this invention is the provision of a brick wallwhich does not require expensive wooden studding to complete the wallinto a finished wall.

Another object of the present invention is to provide a unique brickunit for use in a reinforced single wythe wall which provides foradditional reinforcement at corner joints. A related object of theinvention is to provide a unique brick for a reinforced wall whichreadily adapts for use at window and door openings.

These, and other objects and advantages of this invention willhereinafter appear and for purposes of illustration, but not oflimitation, an embodiment of this invention is shown in the accompanyingdrawings in which:

Figure 1 is a perspective view showing a portion of the exterior side ofa wall broken away to illustrate the reinforcement;

Figure 2 is a perspective view partially in section of the interiorportion of the wall illustrating the various stages of erection of thecomplete wall;

Figure 3 is a perspective view of the brick unit used in theconstruction of a wall;

Figure 4 is a perspective view showing the same brick unit with openingstherein to reduce the weight;

Figure 5 is a top plan view of a section of the wall fully constructedbut without the addition of insulation, lath, plaster, etc.;

Figure 6 is a top plan view of a segment of one of the brick units inthe wall showing a channel and a mold;

Figure 7 is a top plan view of a segment of one of the brick units inthe wall showing the channel and mold filled with grout;

Figure 8 is a top plan view of a segment of one of the brick units inthe wall showing the reinforcement, insulation and lath added thereto;

Figure 9 is a top plan View of a segment of one of the brick units inthe wall showing the reinforcement, insulation, lath and plaster addedthereto; and

Figure 10 is a fragmentary view of the mold used to help form thereinforcement of the brick wall;

Figure 11 is a perspective partial view of a wall laid with the brickunits such as shown in Figs. 3 and 4 with like ends together, showingthe positioning of the reinforcing channels;

Figure 12 is a perspective exploded view of the relationship of thereinforcing channels at a salient or outside corner; I

Figure 13 is a top diagrammatic view showing the relationship of thereinforcing areas in the corner joint shown in Fig. 12;

Figure 14 is a perspective exploded view of an inside or reentrantcorner employing the brick units such as shown in Figs. 3 and 4;

Figure 15 is a top diagrammatic view of Fig. 14 showing the location ofthe reinforcing channels at the in-" side or reentrant corner;

Figure 16 is a top view of a modified brick construc-' modified brickconstruction shown in Fig. 16 illustrating.

how a window section is built.

In broad outline the invention contemplates the erect tion of areinforced single-wythe brick wall by employing 4 a unique brick unithaving a central recess and a recess at one corner. According to amodified form of the invention a unique jamb slot is incorporated withthe corner recess which serves the two fold purpose of receiving a sashfin at window openings and also mechanically locking the reinforcementin place along the wall. With whatever form of brick is employed thewall may be erected by using like brick units following the rule: laylike ends together. Such a wall will provide pairs of reinforcingstations on half brick spacing with the pairs separated by one and onehalf brick lengths. At corners, however, where additional strength maybe desired, the pairs of reinforcing stations may be located to flankthe corner joint within a half brick length of the corner. The detailsof the brick unit as well as the wall construction will unfold as thespecification proceeds.

Referring to the drawings, the brick unit in the wall contemplated bythe invention is generally indicated as B (Figure 3) and in all respectshas the same composition as bricks presently manufactured. The brickunit B comprises the usual top 10, bottom 12, side walls 14 and15,'exterior face 16 and interior face 18. A groove 20 is providedsubstantially in the center of the interior face 18 of the brick unit. Apartial cut-out section 22 is also provided at the corner of theinterior face 18 and either one of the side walls 14 or 15. The brickunit may also contain openings 24 to reduce the weight of the brickunit, as shown in Figure 4, without affecting the above describedfeatures of the brick unit.

The brick units are placed into a wall W in the conventional mannerexcept that the brick units in each row or course 26 are generallyplaced in complementary relation: that is, the side wall 14 having thecut-out section 22 must abut the cut-out section 22 in the adjacentbrick unit, or the side wall which does not contain the cutout section22 must abut the uncut side wall 15 of the adjoining brick unit B asshown in Figure 5. Stated succinctly the rule for the mason to followis: lay like ends together. Each course of brick units is also staggeredso that the groove of the upper course overlays the ends walls 14, or 14and 15, or 15 of the course directly beneath.

As will be seen from a careful examination of Fig. 2, the bricks 'whichwere laid in that wall were not in all instances laid with like endstogether. If the mason erects the wall with all like ends of the brickfacing each other the resulting wall construction will be in the natureof that shown in Fig. 11. There it will be seen that the continuouschannels 28 occur in pairs, the centers of the paired channels beingone-half a brick length apart. The distance between the outer channelsof the adjacent pairs is equivalent to the length of a brick and a half.Having this choice available the reinforcing steel rods 30 and adjacentgrout casement 38 such as shown in Figs. 1 and 2 can actually be doubledover the amount shown in Figs. 1 and 2. In locations where particularlystrong reinforcement is desired, such as in California and other areaswhere earthquake resistance is an important factor, the unique brickconstruction makes this possible in a single wythe wall.

Another unique feature of wall made with the brick 10 is illustrated inFigs. 12 through 15, where the erection of outside and inside or salientand reentrant corners, respectively, are shown. As will be seen fromFig. 12 a typical overlapping corner joint construction is shown.Because the brick 10 is recessed only in one end corner, a perfectlysmooth outside face is presented at the exposed corner formed by theuninterrupted brick ends 15. The further advantage of the unique brickunit in the corner construction is better illustrated in Fig. 13 whereit will be seen that pairs of reinforcements 38 occurs immediatelyadjacent the corner construction which, of course, makes it possible tomore securely reinforce the wall at the corner. In addition, thisinsures the positioning of the reinforcement 38 and attendant fasteningmeans 48 (such as shown in Fig. 2) close to the inside corners so thatthe inside wall construction may be ade quately supported near itsinside joint.

An inside or reentrant corner construction using the same type of brick10 is illustrated in Figs. 14 and 15. There it will be seen that thereinforcing channels 28 occur again as a pair located only a half abrick length away from the corner joint itself. The advantage of locating the reinforcing and fastening elements close to the vertex of theinside corner is even more important when the function of the strips tosupport the inside finished wall is considered. Thus it will be seenthat by using the unique brick the longest unsupported span of insidefinished wall material will be the length of only one brick, and in thecase of the most common corner, this unsupported length of inside wallmaterial would be only one-half the length of the brick unit employed.

After the wall has been so constructed, a steel rod 30, or the like, maybe inserted into the channel 28 and a mold form M comprising side walls32 and 33 and a connecting wall 34 is placed tightly against and securedin any conventional manner to the brick units B which surround and intowhich the channel 28 is formed. Thus the mold M encases the channel 28,as shown in Figure 6. Grout 36, preferably quick setting. grout, isthen.

poured into the channel and mold form until the channel and mold formare completely filled with the grout 36. When the grout 36 has set themold M is removed leaving a cement reinforcement '38 having thestrength, rigidity and durability required for single-wythe load bearingwalls.

For convenience of finishing the brick wall W with insulation 40, lath42, plaster 44, etc., the mold M may also have openings 46 to receivenails 48, or the like. When nails 48 are used, the heads 50 of the nails43 are fitted into the openings 46 of the mold on the inside of the moldform so that the heads 50 rest on the inner surface of the connectingwall 34. The mold is then placed againstthe wall in the manner describedabove. After the grout 36 has been poured and before it has set, thenails 48 may be pushed inwardly into the grout 36 (see Figure 7)sufficiently to insure a strong and permanent imbedding of the nails 48in the reinforcement 38 when the grout 36 has set. Of course, doubleheaded nails 52 may also be used (Figure 8).

The brick wall W can easily be finished as desired by applying theinsulation 40 against the wall and allowing the nails 48 imbedded in thereinforcement 38 to penetrate the insulation 40. Because thereinforcement 38 extends out from the brick Wall W for a short distantea cavity 54 is generally formed between the wall W and the insulation 40which contributes to the insulating qualities of the wall as well as tohelp prevent water. penetration. Lath 42 may then be applied in theaccepted manner. The ends of the nails 48 may then be struck down orout, as shown in Figure 2, to secure the lath 42 and the insulation 40to the wall. Obviously, by imbedding the nails 48 in the reinforcements38 the necessity of drilling holes for or driving nails, which isgenerally difficult and unsatisfactory, is eliminated and at the sametime a rapid and permanent means for securing the insulation and lathare substituted therefor.

A modified form of the brick illustrated in Figs. 3 and 4 is illustratedin Fig. 16. The modified brick 1.00 differs from the other brickconfiguration in the nature of the corner groove which includes a uniquejamb slot 101. The jamb slot 101 comprises a recessed leading face 102followed by the J shaped jamb slot 101, its basic geometry being that ofan isosceles trapezoid. The base 104 of the jamb slot is parallel withthe end 105 of the brick unit and located at a depth sufficient toaccommodate a sash fin or similar window construction element. Thecentral grove 20 remains as in the basic brick discussed above.

The distinct advantages flowing from the modified brick 100 are bestillustrated in Fig. 17 where it will be seen that a vertical sash slot110 may be built at a window opening to receive a sash fin 111 whichsubsequently cooperates in holding the window sash 112. Anotheradvantage fiowing from the modified jamb slot construction lies in thenature of the vertical reinforcing column recesses 128 which havealternating jamb slot configurations and U-shaped recessedconfigurations. When the reinforcing rod 30 with its molded reinforcingsare molded, the grout will migrate into the base 104 of the jamb slotand thereby key the reinforcement against lateral and longitudinaldisplacement adding additional strength to the wall. This featurepermits a grout to be used which has low surface adhesion properties andyet provides a reinforced column 38 which can hear an extensive lateralloading.

In review it will be seen that by using the unique brick as well as itsmodified form, a reinforced single-wythe wall may be erected which issusceptible of extensive reinforcement. The corners may be built fromhomogeneous brick units with the outer faces uninterrupted by unsightlyslots, or requiring extensive patching or breaking of bricks in theerection. Provision is made for reinforcing columns closely adjacent tothe corner on the inside wall where support for the inside wallconstruction is more desirably located. In addition, by employing amodified construction, provision is made for mounting window sash andlocking the reinforced columns against lateral or longitudinaldisplacement from the wall.

We claim as our invention:

1. A reinforced brick wall comprising a plurality of rectangular brickunits having inside, outside, and end faces and laid horizontally inrows with the brick in adjacent rows staggered relative to each other,each unit having one end face uninterrupted and a central groove on theinside face of the brick and a partial groove on a single inside cornerof the brick at its other end, the bricks being laid in the wall withthe partially grooved ends facing each other and the uninterrupted endsfacing each other so that the inside of the wall presents pairs ofvertically aligned grooves spaced horizontally a distance ofapproximately one-half brick length.

2. A reinforced brick wall comprising a plurality of brick units, eachbrick having an inside and an outside face and a pair of end faces, oneof said faces being uninterrupted, means defining a central verticalgroove on the inside face, means on said inside face defining a partialvertical groove at one end of the face, the bricks being laid in thewall horizontally in rows with the grooved ends together and theuninterrupted ends together and presenting pairs of vertical groovesspaced apart along the Wall approximately one-half brick length, theadjacent pairs of vertical grooves being separated by a distance ofone-and-one-half brick lengths, and reinforcing means positioned withinsaid pairs of vertical grooves and secured to the brick defining suchgrooves.

References Cited in the file of this patent UNITED STATES PATENTS591,788 Pennie Oct. 12, 1897 1,039,313 Mitchell Sept. 24, 1912 1,661,739Sentrop Mar. 6, 1928 1,675,093 Conley June 26, 1928 1,771,302 Lane July22, 1930 2,033,831 Jensen Mar. 10, 1936 FOREIGN PATENTS 20,366 GreatBritain of 1913 587,987 France of 1925 OTHER REFERENCES Brick and ClayRecord, page 45, October 1944.

